API OICS

Guided Wave Radar

Probe types and applications
By
Kevin Martyn
Magnetrol
April 14/08
 Types

Coaxial Twin Single rod

Dual element probes, no beam spread, high sensitivity. Single element probes, less
sensitivity. High build up
resistance. In a matched chamber
performs like a coaxial probe

Selecting the right probe is key to the application, in both electrical and mechanical aspects.
It their simplest form they are just a rod in a process, made with compatible metal, that can be cut,
bent, or coated to suit the application. Over 20 types to choose from, that fall into two simple
categories, single or dual element. Twin and Single Rod Probe can be rigid or flexible.
 Anatomy and function of GWR Probes
To better understand their application, lets look at what they do.

End of Probe Pulse

Fiducial Pulse Level Pulse

 Anatomy and function of GWR Probes

End of Probe Pulse

Fiducial Pulse Level Pulse

Let’s break our look at this into 3 sections.

Starting at the top of the probe
• Engineered impedance change (Fiducial) causes a reference reflection in the probe
gland rather that in the vessel where it can cause error (transition zone) or complete
loss of signal (blind zone). This allows a true overfill rated device, as opposed to “hold
last value” approaches and their associated risk. This contributes to their suitability as
SIL 2 devices. Deadzones, null areas, transition zones etc. can now be avoided in
almost all applications
• Delay line which connects the electronics to the probe is a predetermined length (9”
Typical) . The fiducial is continuously measured to verify calibration and accuracy. Can
be extended to 15 feet for convenient remote electronics.
• The process seal is also contained in this section. Certified to ISA 12.27.01, confirming
reliability of both hard bonded, and soft (o-ring) type seals. Our seals are tested up to
16,000 psi by accredited 3rd party agencies. Seals can be bonded borosilicate glass
(hermetic) or a variety of o-rings materials combined with other materials like Teflon,
Peek , or alumina, depending on application requirements.
• A reference target is added to the probe a few inches below the gland, in those cases
where the dielectric of the upper gas vapor is variable and high enough to start
impacting accuracy (steam). It measures and provides correction of error. With this
compensation algorithm, boiler drum level, feed water heaters and flash tanks
become excellent applications.
 Seal types and related applications
Hard bonded seals, and soft o-ring seals
Hard Seals
• Contain borosilicate glass
• Rated to 800F or 6250 PSI
• Hermetic seal useful for full-vacuum applications
• Rated to -320F for cryogenic applications
• Must be used for ALL anhydrous ammonia and chlorine applications
• Not a good choice for saturated steam

Soft Seals
• O-ring material selected for application
• Faced with TFE, Peek, or Alumina, to suit application
• 650F or 2400 PSI
• Suitable for vacuum, but not true hermetic

Spacers (coax probes)

• TFE, Peek, or alumina
The level reflection

• Correct probe / chamber / electronics

configuration will yield a suitable level
reflection in even the lowest dielectric media
• There will be one reflection in overall level
application or two reflections in interface
applications.
• The second (interface) reflection can be
generated with any probe type.
• The standard electronics looks at the distance
between the two reflections and corrects for
the time of flight delay through the
hydrocarbon layer.
• Probe reflections can easily be observed and
optimized with free industry standard FDT
software.
Interface Measurement

Interface Specifications:

• Top Layer r = 1.4 to 5

• Bottom Layer r > 15

• Probes to 40 feet

• Tracks upper edge of emulsion

• Emulsion can be several feet

• Resolves 1-2 inch of hydrocarbon even in high temperature apps

• Coaxial probe, 500cP

• Enlarged Coaxial probe or Twin Flexible probe, 2000cP

• SRP in matched chamber

 Interface Level measurement & Emulsion Layers

Does overall level vary,

as well as interface?
Air Air
GWR will track here
Oil Clean interface or Oil
emulsion?

Rag Layer

Water Water

Clean Interface Rag Layer

Do you have one variable (interface) or two (overall level and interface). Many technologies can handle
only one variable. A second will introduce substantial error.
End of Probe reflection
• In low E applications, or when there is no level on probe, this
signal can be seen a verified to be in the correct location. A
helpful diagnostic.
• This EOP signal does move with level on the probe, but should
not be used to infer level (EOP following) as it is affected by
dielectric changes in the media, and offers poor resolution and
accuracy.
 Probe Choice Is Critical!
Must Consider…..
 Viscosity
 Temperature
 Material compatibility
 Pressure
 Seal / O-rings
 Steam
 Turbulence
 Mounting fitting
 Obstructions/proximity effects
 Length
 Overfill considerations
 Head room
 Dielectric sensitivity
 Coating/bridging/buildup
Probe types
 Probe Configurations
Coaxial Probe

Coaxial Probe

• 0.375” (10mm) rod inside of a 0.875” (22 mm tube (standard)

• 0.6” (16mm) rod inside a 1.75” (45 mm) tube (enlarged)
• Most efficient waveguide, Er > 1.4
• No proximity effects.
•Reads level accurately to the very top (no transition zone)
•Suitable for very high RF fields
•Viscosity < 500 cp (standard)/ <2000 cP (enlarged)
• High Temperature, High pressure versions (800F or 6250 PSI)
• Probe lengths to 20 Feet rigid
• 316 ss standard. Hastelloy and Monel optional
•Single bottom spacer for viscous applications
Bottom View
•Optional flushing connection allows CIP without process Electromagnetic Propagation
interruption
 Probe Configurations
Twin Rod Probe

•Two 0.5” (12 mm) parallel rods

• General purpose probe, Er > 1.9

• 3” or larger chamber

• Viscosity < 1500 cp

• Rigid Probe lengths to 20 feet (6 meters)

• FEP Coated Flexible Probes to 75 feet (22 meters)

• 316ss (std.) Hastelloy and Monel optional

Bottom View
Electromagnetic Propagation
 Probe Configurations
Single Rod Probe

• Solid 0.5” (12mm) rod Single Rod Probe

• Er > 1.9 when used in chambers, 1.4 if impedance matched.

• Er > 10 when used in open vessels
• High viscosity applications (<10,000 cP)
• Immune to high dielectric buildup
• Rigid probes to 20 feet, flexible cable to 75 feet
• Exotic metals and PFA coating optional

The least sensitive probe also has a large impedance change as the signal enters the vessel
which can cause a small blind area at the top. Mounting in a matched chamber turns it into a
large coax probe, making it very sensitive and overfill suitable.

The larger the launch plate (flange, top of tank), the better the performance.
Yes you can really bend it!
Probe mounting
Chambers and nozzles
Invasive or bridle mounts – present different issues

Single rod probe in a

matched chamber gives
constant impedance and
coax performance.
Typical approach in refineries, & chemical plants

• Isolation allows maintenance without

interrupting the process.
• Chamber is sized and matched to
instrument characteristics.
• Option for redundant indicator (MLI).
• B31.3 piping code typical
• NACE, insulation, heat trace optional
• Available as a complete package.
 Temperature effect

Cooler product becomes more dense, and indicates a lower

level for same weight. Insulation & heat tracing can help.
 Why “Overfill Safe”?

•Overfill probes can measure to within specification all the way up

to the process seal
LLSD - 1208
•Important in cage applications

•Don’t go blind! ?
Piping Configurations
 Single Rod Probe

nozzles

C
A = Diameter ______

B = Length ______
B
A C = Mounting ______

Note: A divided
Note: by B
divided should be >or= 1 for optimum performance

2"x6" (50x150mm) nozzles (typ.) will force increased

BLOCKING DISTANCE and possible decreased SENSITIVITY
 Bent Probe with built in chamber
Popular displacer level transmitter replacer
Before After
 Coaxial vs. SRP invasive vs SRP

Coaxial Probe Single Rod Probe

Fiducial Fiducial
No unwanted
changes in
Mismatch depending on
impedance
mounting

Level Level
 Coaxial vs. Single Rod Probe
Coaxial Probe Single Rod Probe in Stillwell/Cage

Fiducial Fiducial
No unwanted
changes impedance
Smaller mismatch
depending on chamber
dimensions

Level Level
 Frequently Asked Questions
Q: Is the probe matched to the electronics, such that I need to select a certain combination for my
application?
A: No, the electronics quick connect to, and work with any probe. It is the probe and optional chamber you
select for the application, not the electronics. Electronics are typically selected to meet area classifications.

Q: I am replacing displacer transmitters that came with chambers, can I do the same with GWR?
A: Yes this matching chambers are becoming increasingly popular, However you may be able to use the
existing chamber with a new GWR probe as well.

Q: Do GWR probes work if the application is producing steam?

A: Yes, but only if a steam probe with compensating reference target is selected.

Q: I have a vacuum tower application, any special concerns?

A: Yes, you should select a probe that accurately reads to the face of the probe, and you may also want a true
hermetic seal.

Q: Can I cut the probe if it is too long.

A: Yes, please request the appropriate procedure from the manufacturer.

Q: What about liquid /liquid interface applications?

A: Fine for a standard unit, but if non invasive (in a bridle), make sure you have sufficient equalization
connections, if it is not flooded service.

Q: What about critical overfill applications?

A: Select a probe that has no transition zone for accuracy and reliability to the very top of the probe.
Questions?
 E-mail kmartyn@magnetrol.com for additional info, or a copy of this presentation.

For the internal use of API OICS

This presentation contains Magnetrol proprietary and confidential information. Do not reproduce or distribute without written permission